HSE information sheet
Health hazards from dusty cargoes during
the loading and unloading of ships
Introduction
This information sheet is one of a series prepared by HSEs
Docks National Interest Group. It lists the potential health hazards
from handling dusty cargoes in docks, outlines the main legal
requirements and describes methods of controlling the hazards. It
does not cover the control of dust under environmental protection
legislation, or fire and explosion hazards.
Millions of tonnes of dusty cargoes are handled in UK ports every
year. Those causing concern include grain, soya, peas, beans,
animal foodstuffs, fishmeal, ores, coal and coke, aggregates
containing quartz, cement, cement clinker, triple superphosphate
and other fertilisers. During handling these can give off large
quantities of dust; the more they are handled the more dusty they
become. In some cases, eg coal and aggregates, the dust is
simply small particles of the material itself. In other cases, eg
grains and pulses, the dust may include contaminants such as
bacteria and fungi.
Health hazards
Different dusts have different effects on health,1-4 but the most
important effects of dusty cargoes are on the lungs; the chronic
effects are often permanent and disabling. The diseases
caused include chronic bronchitis, occupational asthma, grain
fever, farmers lung and pneumoconioses such as silicosis.
Some of the dusts cause sensitisation. Early indications include
irritation of the eye or nose, or skin rashes. People who become
sensitised (allergic) to a dust need to avoid exposure completely.
If they get help when they have early indications, they may be
able to prevent more serious effects.
When do the legal requirements apply?
The Control of Substances Hazardous to Health Regulations
1994 (COSHH) apply to work with dusts which are hazardous
to health.5, 6 A dust is considered to be hazardous to health if:
it has an occupational exposure limit, ie it has been given
an occupational exposure standard or a maximum
exposure limit;
it is present at a substantial concentration in air, ie more
than 10 mg.m-3 (total inhalable) or 4 mg.m-3 (respirable)
unless there is indication of a need for a lower value;
it is classified as dangerous to health (ie as very toxic,
toxic, harmful, corrosive or irritant) under the Chemicals
(Hazard Information and Packaging for Supply)
Regulations 1994;7
it is a biological agent, ie it contains bacteria or other
microbiological organisms; or
it presents a hazard to health comparable with any of the
above.
Docks Information Sheet No 2 (Revised)
Occupational exposure limits (OELs)
COSHH defines two types of occupational exposure limit:
Maximum exposure limit (MEL). This should never be
exceeded. Employers must reduce the dust levels to which
people are exposed as far below the MEL as is reasonably
practicable; the levels should not exceed the MEL when
averaged over a specified period.
Occupational exposure standard (OES). This is the level of
dust at which there is no evidence of injury to people
exposed day after day. Employers must reduce exposure by
inhalation to at least that level. If exposure exceeds an OES,
employers must find out why and take action to reduce
exposure to the OES as soon as is reasonably practicable.
The current OELs are listed in HSE Guidance Note EH40
Occupational exposure limits.8
Most OELs for dusts are set as time-weighted averages (TWAs)
over eight hours. These are long-term exposure limits and are
intended to restrict the total intake over a whole working day.
Short-term exposure limits (STELs) are set for some
substances which can damage health on brief exposure. These
are usually averaged over 15 minutes. If there is no STEL, it is
recommended that a figure of three times the long-term limit is
used as a guideline for controlling short-term peaks in
exposure. For instance, grain has a MEL of 10 mg.m-3 eight-
hour TWA and no STEL, so it is recommended that exposure
over any 15 minutes does not exceed 30 mg.m-3.
Some dusts do not have a specific occupational exposure limit
listed in EH40. In these cases COSHH applies if personal
exposures exceed 10 mg.m-3 eight-hour TWA for total inhalable
dust or 4 mg.m-3 eight-hour TWA for respirable dust, unless
there are indications that a lower level should apply.
Table 1 shows some of the main cargoes giving rise to dust, the
primary health effects and current OELs.
Common levels of dust
Table 2 gives examples of dust levels measured while loading
and unloading grain from ships. Dust levels produced during
the handling of other cargoes are equally significant. For
example: silica exposures of 2.5 times the MEL have been
measured in a ship unloading stone; and personal exposures
up to 20 times the OES when unloading coal and coke.
Personal exposures will depend on the precise circumstances;
in dock operations it is likely that some of the people could be
exposed to dust concentrations over the OEL.
What is required when COSHH applies?
Assessment
A COSHH assessment9 needs to assess the risks to health,
taking into account how the dust causes harm, how it gets into
Table 1 Dusty cargoes, their effects and OELs the body (eg by breathing, or by skin contact or by swallowing)
and the likely levels to which people will be exposed. It also
Cargo Agent Health effect Exposure limit needs to:
eight-hour TWA
consider whether exposure to the dust can be prevented;
Aggregates Crystalline Silicosis MEL 0.3 mg.m-3
(quartz bearing) silica respirable dust
if exposure cannot be prevented, identify what is needed
Cement Portland Possible -3
OES 10 mg.m total to achieve adequate control (in other words the steps
clinker cement dust irritation and inhalable dust, needed to reduce exposure to the OES or to as low a level
reduced lung 4 mg.m-3 as is reasonably practicable below the MEL);
function respirable dust
identify the arrangements required to ensure the proper
Coal Coal dust Possible OES 2 mg.m-3 use and maintenance of control measures;
reduced lung respirable dust
function
consider whether exposure needs to be monitored;
Fertiliser (eg Dust Possible Not set*
urea, potash) - reduced lung identify any health surveillance required; and
see below for function
triple super- identify any information, instruction and training requirements.
phosphate
The assessment should be written down. It must be reviewed
Fishmeal Dust Possible Not set** regularly, and whenever there is reason to suspect that it is no
respiratory longer valid or circumstances have changed significantly.
sensitisation Reviewing means checking whether the existing assessment is
still adequate and, where necessary, amending it. It does not
Grain Dust Respiratory MEL 10 mg.m-3
sensitisation total inhalable dust
mean repeating the whole assessment.

Soya, peas, Dust, Respiratory Not set** Control measures

beans endotoxin sensitisation
The most effective and reliable control measures should be used,
Triple super- Phosphoric Possible OES*** with personal protective equipment (PPE) a last resort. PPE may
phosphate acid respiratory only be used as the sole method of control if it is not reasonably
tract irritation practicable to take any other steps to reduce exposure.

Notes Measures which control exposure to dusty cargoes include:

keeping away people who do not need to be in dusty areas;

* COSHH applies if personal exposures exceed 10 mg.m-3 eight-
hour TWA (total inhalable dust) or 4 mg.m-3 eight-hour TWA (respirable
dust) unless there are indications that a lower level should apply
** Possible sensitiser so exposure needs to be reduced to a level as
low as reasonably practicable
*** Triple superphosphate can contain up to 50% free diphosphorus
pentoxide which has a short-term OES of 2 mg.m-3 (total inhalable)
using totally enclosed, continuous handling systems -
these usually provide the best control and should be used
whenever reasonably practicable;
enclosing transfer points, eg between conveyors;
enclosing the bottoms of discharge chutes and spouts with
correctly adjusted socks and skirts;

using telescopic cascade chutes - kept properly adjusted,

these dramatically reduce dust levels during bulk loading,
Table 2 Examples of grain dust levels measured while loading and minimising the distance of free fall;
unloading ships (MEL 10 mg.m-3 eight-hour TWA)

Operation Dust levels

enclosing the boots or hoppers of conveyors as far as
(mg.m-3) possible, and discharging them via a spout with a
correctly adjusted sock or skirt;
Unloading ship using bucket elevators 1-14
suppressing dusts with sprays of water or edible or mineral
Elevator operating (in cabin) 1.5-7
oil or other binding agents;
On quay adjacent to barge being loaded 69-267
Driving vehicle in hold of ship 13-32 not tipping material directly down chutes into holds - this
generates great quantities of dust. It is much better if
Cleaning holds and quays 14-23 lorries are discharged evenly into the boot of a conveyor
Loading lorries 1-30 which can then discharge to the required area of the hold;
Discharging lorries 7-17
not unloading by grab - this generates large quantities of
People in vicinity of operations 1-6 dust. When it is unavoidable:
 - use closed (covered) grabs to prevent overfill,
encourage clean run-off and prevent wind stripping;
- maintain the jaws to prevent leakage;
- use a hopper into which the grab discharges to load a
lorry or a conveyor;
- minimise the drop height by opening the grab within
the hopper;
- minimise the free height from the hopper to vehicle, and
enclosing the loading point as far as is reasonably
practicable;
- fit hoppers with extraction and or baffles; and
planning the work to eliminate or minimise the need for
trimming holds and to avoid creating slopes of material
which are so steep that they are liable to collapse and
create more dust.
If trimming cannot be avoided and a vehicle is used, the cab should
have dust filters. Suitable dust filtration systems should be fitted to
the cabs of all new loading shovels used to handle dusty cargoes.
More detailed information on the control of dust during loading and
unloading operations and on extraction systems is given in
references 10 and 11.
Respiratory protective equipment (RPE)
When loading or unloading dusty cargoes, RPE12-14 may be
needed in addition to other control measures, particularly when
trimming. Any RPE provided must be suitable for its purpose
and the wearer, and compatible with any other personal
protective equipment needed. RPE must be maintained so that
it works properly.
The RPE must provide adequate protection against the
environment in which it is used. For example, the drivers
short-term exposure to dust could easily be over 30 mg.m-3
when trimming a hold of grain using a loading shovel without a
cab filter. A simple half-mask respirator would not reduce
exposure as far below the MEL as is reasonably practicable,
as equipment providing better protection, such as positive
pressure RPE, is readily available. Powered respirators with
helmets are often used in the docks industry, particularly for
operations where dust levels are likely to significantly exceed
the OEL, for example trimming holds or working on the quay
close to the source of the dust.
When providing RPE ensure that:
the wearer is sufficiently physically fit to cope with the
demands of working with RPE;
it fits well, taking into account facial characteristics - facial
hair reduces the effectiveness of any RPE which relies on
face seals (powered helmets or visors, air-fed hoods and
blouses, or air-fed suits are more suitable); equipment with
full face masks is generally not suitable for people who
wear glasses;
it does not interfere with the demands of the job, for
example, work rate and the need to move around,
communicate and have good visibility;
there are adequate storage arrangements for the RPE;
it is kept clean and inspected each time it is used;
the filters of non-disposable RPE are changed as necessary.
Maintenance
The maintenance of control measures is vital. This applies not
only to dust extraction equipment, but also to RPE and
mechanical handling plant such as elevators, suction legs and
grabs. All should be examined at appropriate intervals. Local
exhaust ventilation plant must be examined at least once every
14 months.11
Monitoring of exposure
COSHH requires monitoring of employee exposure to dust
when it is necessary to ensure that adequate control is
maintained.6 Routine monitoring is not necessary where
reliance is placed on RPE. However, air sampling may be
needed as part of the COSHH assessment to help select the
correct RPE.
Health surveillance
Health surveillance is required for workers who are exposed to
dusts which are respiratory sensitisers, such as grain and
soya, and those exposed to respirable crystalline silica where
there is a reasonable likelihood of silicosis.
Workers exposed to known sensitisers require high level
health surveillance; those exposed to possible sensitisers
require at least low level surveillance, and some may need
medium level surveillance. Booklet L55 Preventing asthma at
work3 describes what is involved.
Workers regularly exposed to silica above 0.1 mg.m-3 eight-hour
TWA (measured as respirable crystalline silica) should be
subject to health surveillance consisting of a respiratory
questionnaire and chest X-rays, as described in Guidance Note
EH59 Respirable crystalline silica.15 The advice of an
occupational health professional is needed when making
arrangements for medical surveillance.
Information, instruction, training and supervision
Workers need to know how to minimise exposure to dust, when
to use respiratory protection, how to clean it, how to replace the
filters and how to test that it is working properly. It is important
that they receive clear information on the nature of the
substances being handled, the risks to health, the early signs of
ill health, and how the controls in use should work. They need
to be properly instructed on the correct procedures and use of
control measures, including the setting up, adjustment and
operation of handling equipment such as conveyors and grabs.
Line managers need to provide adequate supervision to ensure
control measures are properly used.
Involvement of employees
The Safety Representatives and Safety Committees Regulations
1977 and The Health and Safety (Consultation with Employees)
Regulations 1996 require employers to consult their employees
and their representatives in good time about specified aspects of
their health and safety at work. In practice employers have
found that it is beneficial to involve employees and their
representatives in all aspects, including risk assessment.16
References
1 Dust: General principles of protection EH44 (Third
edition) HSE Books 1997 ISBN 0 7176 1435 2
2 Grain dust EH66 HSE Books 1993 (Third edition)
ISBN 0 7176 1535 9
3 Preventing asthma at work: How to control respiratory
sensitisers L55 HSE Books 1994 ISBN 0 7176 0661 9
4 Medical aspects of occupational asthma MS25 HSE
Books 1991 ISBN 0 11 885584 0
5 Control of Substances Hazardous to Health
Regulations 1994 (SI 1994/3246) as amended by SIs 1996/138
and 1997/11, HMSO ISBN 0 11 043721 7, ISBN 0 11 063430 6,
ISBN 0 11 663577 9
6 General COSHH ACOP and Carcinogens ACOP and
Biological agents ACOP. Control of Substances Hazardous to
Health Regulations 1994. Approved Codes of Practice L5 HSE
Books 1997 ISBN 0 7176 1308 9
7 Chemicals (Hazard Information and Packaging for
Supply) Regulations 1994 (SI 1994/3247) as amended by SIs
1996/1092 and 1997/1460, HMSO ISBN 0 11 043877 9,
ISBN 0 11 054570 2, ISBN 0 11 063750 X
8 Occupational exposure limits EH40/98 HSE Books
1998 ISBN 0 7176 1474 3 (updated annually)
9 A step by step guide to COSHH assessment 1993
HSG97 HSE Books ISBN 0 11 886379 7
10 Guide to the handling of dusty materials in ports
(Second edition) British Materials Handling Board 1990
ISBN 0 946637 08 3
11 Introduction to local exhaust ventilation HSG37
HSE Books 1993 ISBN 0 7176 1001 2
12 Respiratory protective equipment: a practical guide
for users HSG53 HSE Books 1990 ISBN 0 7176 1198 1
Printed and published by the Health and Safety Executive
13 Guide to implementing an effective respiratory
protective device programme BS 4275: 1997 BSI
14 Personal protective equipment at work: guidance on the
Personal Protective Equipment at Work Regulations 1992 L25
HSE Books 1992 ISBN 0 71760 415 2
15 Respirable crystalline silica EH59 (Second edition)
HSE Books 1997 ISBN 0 7176 1432 8
16 Consulting employees on health and safety INDG232
HSE Books 1996
Further reading
British Ports Federation Recommendations on the application
of certain health and safety legislation to port operations
Section 4.3 Dry Bulk Cargoes 1991 (Obtainable from PSO
(Technical Services) Ltd, Room 220, Africa House, 64-78
Kingsway, London WC2B 6AH Tel: 0171 242 3538)
The future availability and accuracy of the references listed in
this publication cannot be guaranteed.
Further information
HSE priced and free publications are available by mail order
from HSE Books, PO Box 1999, Sudbury, Suffolk CO10 6FS
Tel: 01787 881165 Fax: 01787 313995
HSE priced publications are also available from good
booksellers.
For other enquiries ring HSEs InfoLine Tel: 0541 545500 or write
to HSEs Information Centre, Broad Lane, Sheffield S3 7HQ
HSE home page on the World Wide Web:
http://www.open.gov.uk/hse/hsehome.htm
This guidance is issued by the Health and Safety Executive.
Following the guidance is not compulsory and you are free to
take other action. But if you do follow the guidance you will
normally be doing enough to comply with the law. Health and
safety inspectors seek to secure compliance with the law and
may refer to this guidance as illustrating good practice.
This publication may be freely reproduced, except for
advertising, endorsement or commercial purposes. The
information is correct at 4/98. Please acknowledge the source
as HSE.
4/98 DIS2(rev) C30